Method of making automobile components by permeating melted copper into gap between elements of steel and cast iron

ABSTRACT

A process of manufacturing an automobile component comprises molding a high strength first element of steel at a temperature about 1550° C.; removing dirt from a surface of the first element of steel and increasing a roughness of surface thereof by sand polishing; placing the first element of steel in a mold; casting a low tensile strength second element of iron on the first element of steel in the mold at a temperature about 1200° C.; cooling the mold; initially polishing a surface of the half-finished component; and diffusing a melted copper into gaps between the first element of steel and the second element of iron at a temperature ranged from about 1080° C. to about 1200° C. to produce the finished component.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to manufacturing processes of automobile components and more particularly to a method of making automobile components by permeating melted copper into a gap between an element of steel and an element of cast iron in a mold.

[0003] 2. Description of Related Art

[0004] A conventional process of manufacturing an automobile component is illustrated in FIG. 1. As shown, the process comprises molding a first element of steel 10, casting a second element of iron 20, placing the second element of iron 20 on top of the first element of steel 10, drilling a threaded hole through the first element of steel 10 and the second element of iron 20, and driving a screw 50 through the first element of steel 10 into the second element of iron 20 for securing the first element of steel 100 to the second element of iron 20. As an end, an automobile component 40 is formed.

[0005] Another conventional process of manufacturing another automobile component is illustrated in FIG. 2. As shown, the process comprises molding a first element of steel 10, casting a second element of iron 20, inserting the first element of steel 10 in the second element of iron 20, and welding contact portions of the first element of steel 10 and the second element of iron 20. As an end, an automobile component 40 is formed after cooling.

[0006] However, each prior art suffered from a disadvantage. For example, in the first prior art the screw 50 tends to loosen or even break after a period of time of use due to the strong vibration of running automobile. As to the second prior art, gaps may be formed between the first element of steel 10 and the second element of iron 20 (see a detailed area in circle A of FIG. 2). The gaps may weaken a structural strength of the automobile component 40. Hence, the automobile component 40 may break after a period of time of use due to the strong vibration of running automobile. Thus, the need for improvement still exists.

SUMMARY OF THE INVENTION

[0007] It is an object of the present invention to provide a process of manufacturing a component for a motor vehicle, comprising (a) molding a high strength first element of steel at a temperature about 1550° C.; (b) removing dirt from a surface of the first element of steel and increasing a roughness of surface thereof by sand polishing; (c) placing the first element of steel in a mold; (d) casting a low tensile strength second element of iron on the first element of steel in the mold at a temperature about 1200° C.; (e) cooling the mold; (f) initially polishing a surface of the half-finished component; and (g) diffusing a melted copper into gaps between the first element of steel and the second element of iron at a temperature ranged from about 1080° C. to about 1200° C. to produce the finished component.

[0008] The above and other objects, features and advantages of the present invention will become apparent from the following detailed description taken with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a cross-sectional view of a conventional process of manufacturing an automobile component;

[0010]FIG. 2 is a cross-sectional view of another conventional process of manufacturing another automobile component, where a contact portion of two constituent elements is greatly enlarged in circle A;

[0011]FIG. 3 is a flow chart illustrating a process of manufacturing an automobile component according to the invention;

[0012]FIG. 4 is a front view in part section of an automobile component manufactured by the process of the invention; and

[0013]FIG. 5 is a cross-sectional view taken along line B-B of FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Referring to FIG. 3 in conjunction with FIGS. 4 and 5, there is shown a process of manufacturing an automobile component in accordance with the invention. The process comprises (a) molding a high strength first element of steel 1 at a temperature about 1550° C. in the embodiment; (b) removing dirt from a surface of the first element of steel 1 and increasing a roughness of surface thereof for the facilitation of a subsequent forming by, for example, sand polishing; (c) placing the first element of steel 1 in a mold; (d) casting a low tensile strength second element of iron 2 on the first element of steel 1 in the mold at a temperature about 1200° C. in the embodiment; (e) cooling the mold; (f) initially polishing a surface of the half-finished product; (g) diffusing a melted copper 3 into gaps between the first element of steel 1 and the second element of iron 2 at a temperature ranged from about 1080° C. to about 1200° C. in the embodiment; and (h) forming an automobile component 4.

[0015] The benefits of the invention include: The first element of steel 1 and the second element of iron 2 are completely united by the copper 3. The process is time saving. High shock absorbing capability of the finished product and durability are carried out.

[0016] While the invention herein disclosed has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of the invention set forth in the claims. 

What is claimed is:
 1. A process of manufacturing a component for a motor vehicle, comprising: molding a high strength first element of steel at a temperature about 1550° C.; removing dirt from a surface of the first element of steel and increasing a roughness of surface thereof by sand polishing; placing the first element of steel in a mold; casting a low tensile strength second element of iron on the first element of steel in the mold at a temperature about 1200° C.; cooling the mold; initially polishing a surface of the half-finished component; and diffusing a melted copper into gaps between the first element of steel and the second element of iron at a temperature ranged from about 1080° C. to about 1200° C. to produce the finished component. 